API 510 Pressure Vessel

Inspector Certification
Course.

Venezuela October 2007.

Review API-510

INTRODUCTION …

¾ Developed By API Sub-Committee On Inspection. First

publication 1934

¾ API Is A Voluntary Organization Comprised Of

Hydrocarbon Operators, Suppliers & Contractors.

¾ Foreword - Document Updates – Applicable Six Months

After Issue.

¾ Updated Regularly.

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SECTION 1…

SCOPE…

SECTION 1: SCOPE...

¾API-510 is a CODE

¾Only Applies To Vessels Placed In-Service

¾ Must Have Authorized Inspection/Engineering Agency.

¾ Alternative rules for E&P pressure vessel inspection

(Exclude of BOK)

¾ Appendix A Defines Exclusions (read code now)

¾Recognizes Fitness For Service (FFS) concept

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SECTION 2…

REFERENCES …

SECTION 2: REFERENCES…

Referenced Documents:

¾API

¾ ASME

¾ NACE

¾ NATIONAL BOARD

¾ WELDING RESEARCH

¾ ASNT

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SECTION 3…

DEFINITIONS …

SECTION 3: DEFINITIONS…

¾For purposes of this code, definitions are fixed in order to

prevent misinterpretation.

¾A great understand of these definitions is elemental.

¾Make sure to know each one.

Read code now

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SECTION 4 …

OWNER USER INSPECTION ORGANIZATION …

SECTION 4: RESPONSABILITIES OWNER/USER ORGANIZATION…

¾ API Authorized Pressure Inspector Qualification & Certification

¾ The Owner User Inspection Responsibilities

¾ API Authorized Pressure Vessel Inspector Responsibilities

¾ Examiners

¾ Repair Organization

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SECTION 5 …

INSPECTION PRACTICES …

SECTION 5: INSPECTION PLAN …

INSPECTION PLAN

VESSELS

INSPECTION
PLAN

SCHEDULE ACTIONS

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SECTION 5: RISK BASED INSPECTION…

¾ Used for determine:

¾ Inspection Intervals
¾ Types of Inspection
¾ Scope of Inspections
Likelihood of Failure and Consequence are required for RBI assessment

SECTION 5: INSPECTIONS PRACTICES …

Preparatory Work

¾ Safety precautions are in this

paragraph, be sure of read and

memorize each one.

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SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Temper Embrittlement: Toughness reduction. Some low alloy. 650 – 1100ºF + Time

¾ Brittle Fracture

Low Low High High High

temperature
+ toughness
+ Hardness
+ Thickness
+ Stress
=

SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Thermal Fatigue : Affect all metals. Cyclical

temperature + different expansion coefficient +
environment

¾ Erosion / erosion-corrosion: Affect all metals.

Velocity + environment + solid particles

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SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Mechanical Fatigue : Cyclical stresses + time

Sudden and unexpected failure. Affect all
engineering alloys.

¾ Atmospheric Corrosion: A form of corrosion due mixture. Affect carbon

steel, low alloys and copper alloyed aluminium

SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾Corrosion Under Insulation: Loss of material or

pitting due water trapped under insulation or
fireproofing. Affect carbon steels, low alloy, 300
Series SS & Duplex

¾ Cooling Water Corrosion: Metal loss due dissolved

salts, gases, organic components and microbiological
activities. Affect carbon steels, all stainless steels,
copper, aluminium, titanium and nickel base alloys

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SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Cooling Water Corrosion: Metal loss, general and pitting

corrosion in condensate return piping. Affect Carbon steels, some
low alloys, some 300 series SS and copper based alloys

¾ Sulfidation: Corrosion for reaction of sulfur

components + high temperature carbon steel and
other alloys.

SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Chloride stress corrosion cracking: Surface

cracking due tensile stress + temperature + aqueous
chloride environment. Affects 300 series SS and
nickel based alloys

¾ Corrosion Fatigue: Cracks under the combined

action of cycled loads and corrosion. Affects all
metals and alloys

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SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Caustic stress corrosion cracking: Cracks in caustic

environment + stress (residual or induced). Affect
carbon steels, low alloy and SS-300.

¾ Hydrogen Blistering: Bubble on surface or

internally. Atomic hydrogen + Cavity on metal

SECTION 5: INSPECTIONS PRACTICES …

¾Damage Modes of Deterioration and Failure

¾ Hydrogen induced cracking: Carbon steels and low

alloy.Wet H2S + stress (residual or induced) + poor
metal fabrication

¾ High Temperature Hydrogen Attack: Carbon steels

and low alloy Cr-Mo-Mn-V. Hydrogen high
temperature + high pressure

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SECTION 5: INSPECTIONS PRACTICES …

5.5 General Types of Inspections

¾ Internal

¾ On-Stream

¾ External

¾ Thickness Inspection

¾ Corrosion Under Insulation

SECTION 5: INSPECTIONS PRACTICES …

5.6 Condition Monitoring Location (CML)

¾ CML Monitoring

¾ CML Selection

5.7 Condition Monitoring Location (CML)

¾ Examination Technique Selection

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SECTION 6: INSPECTIONS AND TESTING

¾5.8: Pressure Test

¾ If the inspector “believe” after repair or alteration

¾ Could include entire vessel or partially component.

¾ The test pressure according with the construction code

SECTION 6: INSPECTIONS AND TESTING

¾ Risk-Based Inspection, approved for a pressure vessel engineer and

authorized by a pressure vessels inspector.

¾ External Inspection at least every 5 years or at the same interval for

internal or on-stream inspection, whichever is less.

¾ Internal & On-Stream Inspection at on half of the estimated

remaining life or 10 years, whichever is less.

READ EACH ONE FROM THE CODE BOOK

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SECTION 6: INSPECTIONS AND TESTING

¾ Pressure Relieve Device

¾ According to API-576

¾ Repair organization with experience

¾ Quality Control System

¾ Testing and Inspection Intervals

¾ Enough to verify reliability

¾ No over five year or ten year in clean services

SECTION 5: INSPECTIONS PRACTICES …

Corrosion Rate Determination

For new vessel or vessel for which service conditions are being
changed:

¾ Data collected from other vessel in similar service

¾ Based on owner/user experience or from publisher data on

vessels with comparable service

¾ Base line + 1000 hours use thickness measurement

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SECTION 7: INSPECTIONS DATA EVALUATION

Remaining Life

tactual – trequired
RL =
Corrosion rate

Corrosion Rate = Metal Loss/Time

CR (LT) = (tinitial – tactual) / time between measurement

CR (ST) = (tprevious – tactual) / time between measurement

BUT, CR (LT) or CR (ST)?

SECTION 7: INSPECTIONS DATA EVALUATION

Maximum Allowable Working Pressure Determination

SE(ta – 2 CR x NII)
P=
R + 0.6 (ta – 2 CR x NII)

Where:
ta : Actual thickness
CR : Corrosion Rate
NII: Next Interval for Inspection

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SECTION 7: INSPECTIONS DATA EVALUATION

Corrosion and Minimum Thickness Evaluation:

¾ (a) Corroded area of considerable size

¾ (b) Widely scattered pits

¾ (c) Alternative procedure for evaluation based on ASME

Section VIII, D-2 (excluded of the B.O.K.)

¾ (d) Corrosion on welds

¾ (e) Corroded areas on heads

SECTION 5: INSPECTIONS PRACTICES …

¾ (a) Corroded area of considerable size

Less Than Equal To 60”

Thickness Average Over Half Diameter Or
20” Whichever Is Less

Thickness Average Over One Third

Greater Than 60”
Diameter Or 40” Whichever Is Less

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SECTION 5: INSPECTIONS PRACTICES …

¾ (b) Widely scattered pits

Ignore If:
No Pit Depth Over 50% required thickness (1/2 treq)

7 Square Inches In An 8” Diameter Circle

Sum Along Any Line Does Not Exceed 2” In

Any 8” Diameter Circle

SECTION 5: INSPECTIONS PRACTICES …

¾ (d) Corrosion on welds

1” or 2 tmin
Total Wide
Toe
for
Toe
Evaluation
1” or 2 tmin

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SECTION 5: INSPECTIONS PRACTICES …

¾ (e) Corroded areas on heads

5.7 (e) (2)

5.7 (e) (1) Use the hemi-

spherical head
Use the formula with R
appropriate head = L for
formula torispherical or
R = K1D for
ellipsoidal

¾ Equipment with minimal documentation:

Important procedure to update vessels information

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¾ Records, four types:
¾ (a) Construction and design information
¾ (b) Operating and Inspection history
¾ (c) Repair, alteration and re-rating information
¾ (d) Fitness-for-service assessments

¾ Exercise:
trequired = You May Need To Calculate Using Minimum Thickness
Rules In ASME VIII.

A Vessel Has Been In Service Since 1979. The Vessel Was Originally
0.735” Thick. It Was Checked In 1983 and Was 0.720” Thick. It Was
Checked Again In 1990 And Was 0.650” Thick. The Last Inspection
In 1994 Found It To Be 0.580” Thick. Calculate Remaining Life and
LTCR, STCR If Thickness Required Is 0.503”

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 tactual = 0.580”
trequired = 0.503”
tinitial = 0.735
tprevious = 0.650
LTCR = 0.735” – 0.580” = 0.155 = 0.010”
15 15
STCR = 0.650” – 0.580” = 0.07 = 0.017
4 4
RL = 0.580” – 0.503” 4.52/2 - 2.26 Years
0.017”

¾ Exercise:
A Vessel Was Inspected New In 1993 And Thickness Was

1.65”. In 1994 It Was Measured At 1.37” And In 1998 1.15”.

Thickness Required Is 0.975”. Calculate The Remaining life

Of This Vessel.

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 REPAIRS, ALTERATION AND RERATING OF
PRESSURE VESSELS …

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

Repairs, Alterations & Reratings.

Repairs Or Alterations – Reverts To Design Code i.e.

ASME VIII.

Repairs & Alterations Must Be Authorized and approved –

By Inspector.

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾Defect Repair:
¾Temporary Repairs
¾Fillet-welded patches
¾ Lap band repairs
¾ Non-penetrating nozzles
¾ Permanent Repair
¾ Weld remove and new weld
¾ Defect remove and new weld building up
¾ Weld overlay of corroded area
¾ Insert plate
¾ Weld overlay and cladding

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾ API-510 allow make repair using alternatives to PWHT, these

alternatives are:

¾ Preheating Method; used when notch toughness is not

required

¾ Controlled-Deposition Welding Method; when notch

toughness is not required.

GENERAL CONSIDERATIONS SHALL BE DONE

BEFORE

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

Preheating Method; limited by:

¾ Only for P1, Gr 1,2,3 and P3 Gr 1,2
¾ Only for SMAW, GMAW and GTAW
¾ The preheat shall:
¾Minimum temperature of 300ºF and maintained during the
welding.
¾ This temperature should reached and maintained to 4” or 4
times thickness to each side of the welding (whichever is great).
¾ The maximum interpass temperature shall no exceed 600 ºF

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

Controlled-Deposition Welding; limited by:

¾ Only for P1, P3 and P4
¾ Only for SMAW, GMAW and GTAW
¾WPS shall be qualified including:
¾ Preheat temperature
¾ Interpass temperature
¾ Post heating temperature
¾Qualification thickness according table 7-1 and no for QW-
451.1.

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

Controlled-Deposition Welding; (cont…):

¾ The test shall be the same material for production weld
¾ The PQR shall include impact test in “as weld” condition
¾ The WPS shall additionally include:
¾ Supplementary essential variables
¾ Maximum heat input no exceeding the qualified heat input
¾ Minimum preheat no less that the qualified
¾ Maximum interpass temperature no exceeding the qualified
interpass temperature
¾ The preheat temperature should reached and maintained to 4” or
4 times thickness to each side of the welding (whichever is great)

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

Controlled-Deposition Welding; (cont…):

¾ Filler metal with diffusible-hydrogen designation lower than H8
¾If used shielding gas, the dew point of the gas shall be under -
60ºF
¾The welding technique shall be controlled-deposition, temper-
bead or half-bead technique. It must be the same in the PQR.
¾ After finish, if used SMAW, the temperature shall be raised to
500 ºF for two hours minimum (if H4 electrode is used this step
can be omitted)
¾ After finish and cool the weld, the final temper bead
reinforcement layer shall be removed

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

What mean temper-bead or half-bead technique?

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾ NDE of Welds, refers to API-577

¾ Usually MT or PT examination for defects

¾ Shall be according the construction code

¾ If originally radiographic was required, new weld require

radiographic also

¾ Acceptance criteria shall be according the construction code

¾ 7.2.5 Local PWHT

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾ Repairs to Stainless Steel Weld Overlay and Cladding

¾ Design

¾ Material

¾ Inspection

¾ Testing

¾ Filler Metal

REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾RERATING:

¾A re-rating change the design temperature, minimum design

metal temperature or its maximum allowable working pressure.
¾ All the following requirements shall be met:
¾Calculations performed by manufacturer or owner/user
engineer
¾Could be used the original or the actual edition of
construction code. Some conditions are applicable. See Figure
7-1
¾Current inspection information is the base for the calculation
and decisions

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REPAIRS, ALTERATION AND RERATING OF PRESSURE VESSELS …

¾ RERATING (cont…):
¾ Pressure test is required, unless:
¾ The pressure vessel has at some time pressure tested to a
test pressure equal to or higher that the required by the rerate
code
¾ Especial NDE evaluation in lieu of testing
¾ The re-rating is acceptable to the engineer
¾ The pressure vessel re-rating will be considered complete when
the inspector witnesses the attachment of an additional nameplate
CBQ

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